Contact lenses and method of making same



Dec. 29, 1953 W. F. HERMAN CONTACT LENSES AND METHOD OF MAKING SAME 2 Sheets-Sheet 1- Filed Oct.- 6 1949 LNVE.NTOR WILL\AM F. HERMAN ATTORNEY Dec. 29, 1953 w. F. HERMAN 2,664,025

- CONTACT LENSES AND METHOD OF MAKING SAME Filed Oct. 6, 1949 I 2 Sheets-Sheet 2 I I IIIIIIIIIL'IIIIIIA I VBNTOR wu. M F. HERMAN ATTORNEY Patented Dec. 29, 1953 UiNl'TE-D PATENT OFFICE CONTACT LENSES AND METHOD or MAKING SAME William F. He man, ismrbrn e, Mass, a si nor to American Optical (lompany, .Southbridge, Massmawvoluntary. association of, Massachusetts AppIication'OctOber 6, 1949,-'Serial-No.1195803 This invention relates-to contactlenses andrhas particular reference to novel means and method of I obtaining relatively i accurate :molds of :pa-

-tients eyes and from which contact lensescan hemade.

A principal object of the invention isto provide novel means and method of initially :taking .:.a

mold of a patients eyesebyforming a. temperature critical fitting lens shaped to the. general shape of the patients eye, causing :thescleral portion of the fittingilens-to assume, .as nearly. aspossible,

the exact-shape of the .scleraof the'qpatientfsfiye, -form ing a oast'from. the resultant-fitting lens, and subsequently forming contact lenses directly from the cast.

Another importantobjectisto provide novel means and method of initially "forming .a fitting lens of a temperature criticalmaterialshaped to the general shape of the visible portion. ofa patients eyeball, causing the .scleral-portion of the fitting lens to assume, .asnearly. as possible, the

exact: shape of the scleraxof thewpatientfs eye; by

inserting the lens over the eyeball pbeneaththe lids and applying heat and light pressure ;to

causesthe scleral portionicto. assumei thegsha-peof the correspondingportion of the eyeball, cooling the lens tomakexit rigid land'toymaintain its shapescharacteristios, and removing and; subse- "quentl-y making a cast from the resultantfitting lens for use'inrmoldi-ng COIltflCbLQlQI-ISQSttO the l shape of thefittin-g. lens. and conse uently to the :shape of thematienflseyeball.

Another object :is :to provide .a fitting lens "formed of a transparent temperature/critica .'ma

terial havinga scleralportion and-a central optic section, the soleral portion. 10f the lens; under ac-- tion ofbody heat and light pressure, .beingada pted to conform, asnearly-as possible togthe shape of the corresponding portion of :.-the eyeball to which itis appliedand upon, subsequent cooling tomaintain saidshape.

Another object is to- 'provide .a fittinglens 10f the above character having :a substantially rigid central optic section and :attemperature critical sclera-l portiomthe opticsection beingadaptedto maintaina spaced-relation with the corneal-portion of the patients :eye during the. fittingzopera- 'tion andif desired, having a prescriptive power therein enabling the lens to ,be nsed-for: zrefnactingi'the patients eye.

Another object is to provide 'a fitting .lens; of the above character, and method of fittingsame, formed with .a substantially strain-free sclelf l portion of transparent temperature.ecritical plastie -material .shaped to theageneral shape-highs .t-Chims. (class-514,5

"tients eye when subjected .rto body h at and slight-pressures and which ,uponncoolin fl 'tain said shape. and-further characterize n he use :of :a colored liquid -by which, the: fittin -may 'befimoreaccurately determined.

.scleral portion of a patients seyeball, gthe zma- 'terial being characterized by its ability 1113.0 re- -main semi-rigidat normal room temperatures and .to be pliable. atbody temperature onatktemperatures slightly above body temperature stand "being-.-readily conform-able toathe shapepf gthe corresponding portion of the --sc.ler.a of ethe-rpaother objects and advantages of ;.th q nventi n will become apparent: from the followin dfiScription. taken .in connection. with the accompanying drawings, in which:

Fig. v1 is ai-rontwiew of ;a plastic fittin lens made in. accordance with the 1 present invention;

Fig. 2 is a transverse sectional viewtakensubstantially ,on"line.,2-2 oiFig. 1;

Fig. 3 is a .a fragmentary s t na view 119 .13. eye showing the initial engagementaof ,a lens th rewith d nsya fi t ns op a ion; 7

Fig. 1 4 is afragmentary sectional iew similar to -Fig. 3 showingtherelation betweenthelens afis deyewhen thelens is finallyfittedto the eye;

-Fis- 51s as cti na iew aapa .che s b m nna-Ives used, o in t a y iormi s th fitt ns lenses;

Fig. 6 is a fragmentary sectional viewofthe ,mold halves when. separated to show the preferred method of placing aplastic disc imposition for molding;

,7 is a fragmentary frontviewcshowing a method of supporting :a fitting lens when used to form casts. therefrom; and

Fig. 3 is a transverse sectionalview-showin' a. modified fittingfllens construction.

,In the ophthalmic profession contact lenses,

which are generally made partly orentirely .of

su s quent alterat o s the et .4 requ red :beicre -anrflccentablend; cqm-iortable fit was obta gd,

h epres n ineuti n v rcomes manyo -,;.the

disadvantages of the prior art by providing means and method of taking a mold of the individual eyeball being fitted and thereafter making one or more accurate contact lenses from the mold, which lenses will possess the desired shape and prescriptive characteristics without requiring repeated trial fittings and alterations.

Referring to the drawings in detail and particularly to Figs. 1 and 2, there is provided in accordance with the invention a fitting lens I shaped substantially to the shape of a contact lens and embodying a central, optic or corneal portion II, an integral intermediate portion I2, and an integral scleral portion I3 formed entirely of plastic material. The plastic material used in forming the fitting lens possesses substantially semi-rigid shape retaining characteristics at room temperature but will, at body or slightly higher temperatures, become very pliant and may be shaped as desired. The preferred composition consists of approximately 85 parts polyvinyl butyral plasticized with approximately 15 parts methyl phthalyl ethyl glycolate and made into sheet form, the sheets being preferably about 1 millimeters in thickness for best results. However, the sheets may, if desired, be appreciably thicker, or may be thinner and used as laminations. It is to be understood that the amount of plasticizer can be varied slightly to produce varying desired characteristics in the resultant plastic material; that is, the amount of plasticizer may be increased slightly, if it is desired to produce a plastic material of a slightly less rigid nature than produced with the preferred composition given above, or the amount of plasticizer may be decreased slightly to produce a more rigid plastic material. This is important since for many reasons it may be desired to use plastic materials having different characteristics such as when the resultant fitting lenses are to be used in exceptionally hot or cold climates.

Other compositions which can be used are: (1) About 85 parts polyvinyl butyral and about 15 parts of dibutyl cellosolve adipate, (2) n-butyl methacrylate, (3) vinyl chloride plasticized to desired consistency with plasticizer, (4) moderately high molecular weight vinyl acetate with plasticizer; or (5) plasticized methyl methacrylate.

Although plastic material in sheet form is preferred for the present method of manufacture of the fitting lenses, it is conceivable that it could be in granular form making the lenses by injection molding methods, or in the case of the plasticized methyl methacrylate material the lenses could be cast.

The fitting lens I0 is shaped substantially to the shape of a contact lens by providing an inner mold half I4 and an outer mold half I5, as shown in Fig. 5, the inner mold half I4 having accurately formed thereon a surface I6 of specific shape and the outer mold half I5 being shaped as desired of the outer or anterior surface of the initial fitting lens ID.

The surface I6 of the inner mold half I4 has accurately formed thereon a large convexly curved surface I8 which has a radius I9 which can be varied in producing fitting lenses of various sizes for accommodating eyeballs of various sizes. It is believed that three sizes of fitting lenses having respective radii I9 of 12, 13, and 14 millimeters will accommodate the large majority of individual eyeballs. A smaller convexly curved surface 23 is also accurately formed 4 on the inner mold half I4, the curved surfaces I8 and 20 being joined by a somewhat short concavely curved surface 2I, all surfaces I8, 20 and 2I having their adjacent edges smoothly blending into one another.

The complementary or outer mold half I5 is provided with a surface I! having a large concavely curved surface 22 and a smaller concavely curved surface 23 which blend smoothly together. These curved surfaces I6 and I! on the mold halves I4 and I5, when the halves are assembled, are spaced to form a mold cavity 24 therebetween of proper size and shape to produce a bell-shaped fitting lens.

In forming a fitting lens in accordance with the preferred method, a circular disc 25 is stamped or otherwise cut out of the plastic sheet material and is inserted in the mold cavity 24 of the outer mold half I5, as shown in Fig. 6. The disc 25 is preferably preheated slightly to render it somewhat pliable so that when pressure is exerted to the disc after it has been placed in the mold cavity 24, it will conform generally to the shape of the surface I1. It is to be understood, however, that the outer mold half I5 may be preheated whereupon the heat will be transferred to the disc 25 to cause the disc to become sufiiciently pliable and conformable to the shape of the surface IT. The method of heating the plastic disc 25 is not important, however, since it is merely necessary that it be heated to such a. state that it is rendered pliable and can be deformed from its original shape. At this time the inner mold half I4 is inserted in the mold cavity 24 and the studs 26 in the inner mold half I4 are threaded to their full extent into the uprights 21 provided therefor on the half I5 to compress the plastic material between the surfaces I6 and IT. The assembled unit is then subjected to heat, preferably in an oven, for about 30 minutes at approximately C. It is particularly pointed out here, however, that the temperature for heating and the time interval can be varied considerably since it is merely necessary that the heat be of sufliciently high temperature and the time interval long enough to fully anneal the plastic material and that the temperature be at a low enough point to prevent decomposition of the material. The plastic material will then become softened and tend to assume the shape of the mold cavity 24. It may be desirable during the heating cycle to again tighten the studs 26 to insure that the flange portion 28 of the inner mold half I4 is in intimate engagement with the adjacent upper ends of the uprights 21. This will maintain the inner mold half I4 within the cavity in the outer mold half I5 to the extent necessary for production of a fitting lens of the desired size specifications.

At the end of the heating cycle the plastic material will be substantially molten and consequently strain free and will entirely fill the lower portion of the mold cavity 24.

When the assembled mold halves I4 and I5 are removed from the heat and cooled, the plastic material will harden and when removed from the mold halves will possess substantially the size and shape desired and the low heat softenable characteristics.

After the fitting lens I!) is removed it can be edge out to exactly the size and shape desired and the edges deburred if necessary. The resultant lens will be shaped substantially as shown in Figs. 1 and 2.

After the fitting lens III has been sized and can be done in :many ways, but gpreferablysby forming a very :small cavity on the :inner or posterior .surface'of the optic section H at the center thereof and-fillingtthe cavity with :a suitable coloring material .to form :a dot 29 which will .be seen through :the plastic material. It may also be desirable-in some instances in order to properlylocate .the fitting lens on thepatientfs eyeball to mark the lens to identify a portion thereof; that is, a .line 30 can :be drawn with suitable coloring material on the portion :of the lens to be positioned over the outer portion of the-eyeball nearest the templeso that' the transverse axis of the lens can-easily .be-identified-when the lens is positioned on -theeyeball.

At this time, the fitting :lens I being substantially rigid, a solution-composed of fiuorescein and sodium bicarb'onate or-.other suitable colored buffer'solution isprepared and 'the lens held so'that the'solution can be poured into it. Prior to this the lensmaybe heated slightly to make it slightly pliant ifdesired. Then, with-'the-patients eyelids 3| retracted, the fitting lens I0 is applied to the-eyeball '32 (Fig. 3) with the buifer' solution 33 being disposed between the eyeball 3'2 and the'lens 10. The eyelids'3l are'then closed portion 3 of itheieyeball, theareasrthereofiwhich still .=r.emain spaced slightly from the :sclera -35 can be gently .massaged. :This will cause massaged scleral areas to conform .to ithe shape of the eyeball. 'Thisrmassagertreatment, however,

should be .very i lightly done .since it :is undesirable .to exert undue pressure "which would cause deformation .of :the vsensitive eyeball. Exudationof the bufier solution :33 will indicate "whether thescleral portion 43 uniformly engages the'sclera 35.

When a fitting lens I0 is properly fittediit will engage the :eyeball substantially as shown in 4 wherein the entire inner surface .of .the ithin scleral portion [3 conforms 'totheiadjacentzscleral portion'35 of the eyeball while the structurally stronger optic section I will remain spaced'from the supersensitive limbus area-'36 of the eye. The opticsection -l'l bein"g of shorter radius andbeing formed with the thick -marginal ring-like --portion 31 formed bythe surface 2| of 'theLinner mold half [4 will'notbedeformedfrom its-initial shape and consequently will remain spaced a predetermined distance from the limbus area '35 "of the eye,'with buffer solution 3-3 remainingonly' such a temperature that it will become quiterigid over-the'lens f0 and body heat will act upon-the and the pressure exerted'by the lids'3l will'cause intermediate portions'thereof to enga'ge'the eyeball 32. This willyof course, cause some of the buffer solution 33 to exude from the space between the lens 10 and eyeball 32, which exudation will ooze out "between the closed lids 3| and "can be easily wiped away.

7 "Uponopening the lids 3|, the lens I0 can be easily positioned by directing its axis line '30 or other identification mark as desired and then locating the 'dot 29 markedin "the optic section directly "over the center of the pupil of the patients eye. However, it may be desirable to mark the "center of 'the optic section at this time rather than before the lens is positioned on-the'eyeball. This method'ispreferred where theflens'seekstomaintain a comfortable fit with the "eyeball while angled slightly or otherwise displaced from what :is originally believed to .be thecorrect'position. 'Sin'ce'comfort is important thisslig'htdisplacenient is permitted and a center can "be marked on the outer surface of the lens with colored crayon or the like. .At this time, "since the buffer solution 33 is colored, the areas in which the .scleral portion ['3 of the lens f0 engagethe eyeball '32 can be easily detected.v Since it is desired that the entire or greater parttofthe scleral portion '13 conform to and assume the shape "of the "adjacent scleral and will retain its'present shape. Suitable means such'as a small suction cup 38 carried by.a'sup-' port 39 can be used to remove the hardened lens I0 as shown in Fig. '4. This can "be "easily done without .pain .to the .patient by retracting the upper eyelid 3| and applying the cup 38 to the upper portion of the lens to and removing the lens by pivoting the upper edge 34 away from the eyeball and then sliding the lens up wardly from beneath the lower 'lid.3|.

At'this time it ispreferable, 'thoughnot essential, to chill the fitting lens IO still more by immersion in cold water or, the like to insure suflicient rigidity .to retain the shape of the patients eyeball.

The next step is to form a cast from the .fltting lens I'D. This is done by merely holding the lens I 0 substantially in the position shown in Fig. 7 and pouring the desired composition into it by conventional means. The composition can be made of any suitable material such as plaster of Paris, dentalstone, or the like which, when poured into'the lens [0 and allowed to stand for a short while, will harden and when removed from the lens I 0 will have substantiallythe shape of the original eyeball to whic'hthe lens lilwas fitted.

This plaster of Paris or "like castwill :when. removed have a slight mark on the center of the optic section which will be made by the small cavity of the dot129. This mark will identify the optic center of'the cast.

From this castthere-can be made-any'number of contact lenses. The final contact lenses'can be made by conventional means and methods such as by initially forming enlarged bell-shaped preformswhich are heated and,employing the phenomena of-plastic memory," collapsed over the cast and "cooled. The resultant article *can then be removed from the cast and cut to the desired contour shape and will possess all the desired shape and size characteristics so that when applied to the patients eye it will fit as nearly perfectly thereto as possible.

The desired prescription will be given to the optic section during the initial forming of the preform. The entire procedure of forming preforms and shaping them into final contact lenses is clearly described in copending U. S. application Serial Number 736,507, filed March 22, 1947.

It is to be understood that the fitting lens l described herein as having an integral optic section II can be provided with an optic section I I made separately and attached to the temperature-critical sclera i3 by suitable means. It is also possible to form the fitting lens II as shown inFig. 8, wherein there is provided a laminated structure embodying inner and outer layers and 4| respectively having therebetween inthe optic section a segment 42 formed of a transparent plastic material having substantially permanently rigid characteristics, such as unplasticized polyvinyl butyral. In forming a lens having such a construction the laminations 40 and 4| can be initially inserted in the mold cavity as thin discs having the rigid segment 42 therebetween, and upon application of heat and pressure in the manner described the entire laminated structure can be made into a substantially integral lens having the desired rigidity in the optic section and conformability in the scleral portion, without the necessity of being provided with the thickened ringlike portion 31 (Fig. 2) on the posterior surface.

It is also to be understood that although the inner mold half I4 is provided with surface curvature 2| for forming the thickened ringlike portion 31 on the posterior surface of the lens ID, the proper reinforcement to prevent deformation of the optic section I I from its initial shape can be provided by inserting a small metallic ring in the material in the area bordering the optic section II or by reinforcing the optic section with a more rigid material.

From the foregoing it will be seen that novel means and methods are provided for making a cast of a patients eyeball, which cast will possess all the necessary shape characteristics required for the efficient production of accurate contact lenses, the entire procedure being easily and efficiently accomplished without pain or excessive discomfort to the patient and without requiring the use of complicated or expensive equipment.

While certain novel features of the invention have been shown and described and are pointed out in the annexed claims, it will be understood that various omissions, substitutions and changes in the forms and details of the means and method illustrated and described may be made by those skilled in the art without departing from the spirit of the invention.

I claim:

1. A fitting lens adapted for use in forming contact lenses comprising a cup-like member that is transparent and has the general shape and size of a contact lens, said lens including a central portion to simulate the corneal portion of a contact lens and a surrounding scleral portion whose inner surface is shaped to the approximate shape of the surface of the average persons sclera, said scleral portion being formed of a temperature-critical, thermoplastic, tough,

transparent synthetic resin and being characterized by its ability to repetitively soften and become pliable when subjected to approximately body temperature and to be relatively rigid and shape-retaining when subjected to normal room temperatures, said lens being positionable over a persons eye wher its scleral portion under slight pressure will conform to the persons sclera under the action of the patients body heat and when removed from said persons eye and subjected to room temperature will hold said shape and be sufficiently rigid and shape-retaining to allow an impression to be taken of the inner surface shape of said scleral portion of the fitting lens which may be then used to form a contact lens having an accurately shaped inner scleral surface.

2. A fitting lens adapted for use in forming contact lenses comprising a cup-like member that is transparent and has the general shape and size of a contact lens, said lens including a central circular portion simulating the corneal portion of a contact lens and having its inner surface of a sharper curvature than the corneal shape of the average persons eye, said lens having a surrounding scleral portion whose inner surface is shaped to the approximate shape of the surfaceof the average persons sclera, said corneal portion having a center mark and the scleral portion having an axis indicating mark, said scleral portion being formed of a temperature-critical, thermoplastic, tough, transparent synthetic resin and being characterized by its ability to repetitively soften and become pliable when subjected to approximately body temperature and to be relatively rigid and shape-retaining when subjected to normal room temperatures, said lens being positionable over a persons eye where its scleral portion under slight pressure will conform to the persons sclera under the action of the patients body heat and when removed from said persons eye and subjected to room temperature will hold said shape and be sufficiently rigid and shape-retaining to allow an impression to be taken of the inner surface shape of said scleral portion of the fitting lens which may be then used to form a contact lens having an accurately shaped inner scleral surface.

3. A fitting lens adapted for use in forming contact lenses comprising a cup-like member that is transparent and has the general shape and size of a contact lens, said lens including a central portion simulating the corneal portion of a contact lens having an inner concave surface of a sharper curvature than the corneal shape of the average persons eye, said corneal portion containing an insert of transparent rigid material to assist said portion in retaining its shape during normal use of the lens, said lens further havinga surrounding scleral portion whose inner surface is shaped to the approximate shape of the surface of the average persons sclera, said scleral portion being formed of a temperaturecritical, thermoplastic, tough, transparent synthetic resin and being characterized by its ability to repetitively soften and become pliable when subjected to approximately body temperature and to be relatively rigid and shape-retaining when subjected to normal room temperatures, said lens being positionable over a persons eye where its scleral portion under slight pressure will conform to the persons sclera under the action of the patients body heat and when removed from said persons eye and subjected to room temperature will hold said shape and be sufllciently rigid and shape-retaining to allow w an impression to be taken of the inner surface shape of said scleral portion of the fitting lens which may be then used in forming a contact lens having an accurately shaped inner scleral surface.

4. A fitting lens adapted for use in forming contact lenses comprising a cup-like member that is transparent and has the general shape and size of a contact lens, said lens including a central portion to simulate the corneal portion of a contact lens and a surrounding scleral portion whose inner surface is shaped to the approximate shape of the surface of the average persons sclera, said scleral portion being formed of transparent polyvinyl butyral sufiiciently and permanently plasticized so as to be characterized by its ability to repetitively soften and become pliable when subjected to approximately body temperature and to be relatively rigid and shaperetaining when subjected to normal room temperatures, said lens being positionable over a persons eye where its scleral portion under slight pressure will conform to the persons sclera under the action of the patients body heat and when removed from said persons eye and subjected to room temperature will hold said shape and be sufficiently rigid and shape-retaining to allow an impression to be taken of the inner surface shape of said scleral portion of the fitting lens which may be then used in forming a contact lens having an accurately shaped inner scleral surface.

5. The method of taking a cast of a persons eye for use in the manufacture of contact lenses and the like comprising the steps of applying over the persons eye a transparent fitting lens having a thermoplastic scleral portion which softens and becomes pliable when so positioned over the persons eye and becomes relatively rigid and shape retaining when cooled to near room temperature and providing a colored buffer solution etween the fitting lens and the persons eye, then as the lens is heated by the patients body applying light pressure to the scleral portion of said lens until the colored buffer solution has been removed, which gives an indication that the inner surface of the scleral portion of the fitting lens conforms to the sclera of the persons eye, then cooling the lens to set the scleral portion thereof to said conformed shape, removing the fitting lens from the persons eye while set to 10 said shape, and while at near room temperature using it as a mold to cast a positive of the scleral surface of said persons eye, said positive being subsequently useful to shape the inner surface of a contact lens blank to fit the sclera of said persons eye.

6. The method of takinga cast of a persons eye for use in the manufacture of contact lenses and the like comprising the steps of applying over the persons eye a transparent fitting lens having a relatively permanently rigid central portion and a surrounding thermoplastic scleral portion which softens and becomes pliable when so positioned over the persons eye and becomes relatively rigid and shape-retaining when cooled to near room temperature and providing a buffer solution between the fitting lens and the persons eye, centering said central portion of the lens with respect to the persons eye, then as the lens is heated by the patients body applying light pressure to the scleral portion of said lens until the buffer solution has been removed, which gives an indication that the inner surface of the scleral portion of the fitting lens conforms to the sclera of the persons eye, then cooling the lens to set the scleral portion thereof to said conformed shape, removing the fitting lens from the persons eye while set to said shape, and while at near room temperature using it as a mold to cast a positive of the scleral surface of said persons eye, said positive being subsequently useful to shape the inner surface of a contact lens blank to fit the sclera of said persons eye.

WILLIAM F. HERMAN.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date 1,834,763 Bonsieur Dec. 1, 1931 2,133,498 Dittmer Oct. 18, 1938 2,178,873 Feinbloom Nov. 7, 1939 2,240,157 Gagnon Apr. 29, 1941 2,241,415 Moulton May 13, 1941 2,250,521 Boeder July 29, 1941 2,300,210 Dittmer Oct. 27, 1942 2,369,758 Sheldon Feb. 20, 1945 FOREIGN PATENTS Number Country Date 493,366 Great Britain Got. 6, 1938 

